Two element building frame members, method and apparatus

ABSTRACT

An enclosed cross-section building frame member has two elongated, sheet metal elements that are connected together by diametrically opposed, double overlapped seams. The elements are generally L shaped and can be compactly stacked for shipping to a construction site. The seams are cross serrated to prevent longitudinal slippage. A portable seaming apparatus has an entry guide tube for assembly of the elements prior to seaming. The apparatus is adjustable for making different sizes of frame members.

TECHNICAL FIELD

The present invention relates to buildings, and more particularly to two element metal frame members, and a method and apparatus for making the frame members.

BACKGROUND ART

In the residential and commercial construction industry there has been, in the last fifty years or so a trend toward the use of roll formed, galvanized, light gauge steel, typically “Cee” or channel shaped elements to replace conventional wood “studs” and other normally wooden frame parts. These light-gauge steel members were initially two by four replacements from gauges of steel as light as 26-gauge, especially where non load-bearing walls were used between otherwise structurally supported floors as in structural-steel framed high-rise apartment buildings and condominium complexes.

In more recent years heavier gauge studs of varying dimensions such as two by sixes, two by eights, two by twelves in up to 14-gauge and more were developed and the machines to roll them for greater load-bearing general structural enhancement for use as cross beams, and ceiling and floor joists. While “Cee”-shaped studs are still commonplace in many forms and gauges, the very nature of the “Cee” shape does not offer the structural integrity of a closed square or rectangular shaped frame element.

Rolling out an unseamed, closed, one-piece element, such as a two by four, a six by four or even a square element, improves the structural capacity and rolling out a properly seamed, closed, one-piece element further improves the structural capacity. However, the weight-to-volume ratio of such sections is only five to ten percent resulting in the shipping of relatively few sections due to volume limitations on trucks, either open bed or box-configured.

DISCLOSURE OF THE INVENTION

A building frame member includes elongated, sheet metal first and second elements that are connected together by diametrically opposed, roll formed, double overlapped first and second seams to form a closed, substantially rectangular shape. The first and second elements can be generally L shaped before seaming. The first and second seams are cross serrated. A method of making a building frame member includes the steps of providing identical, compactly stackable, substantially L-shaped, elongated, sheet metal first and second elements, assembling the first and second elements, forming a first seam between the first element and the second element by roll forming, and forming a second seam between the second element and the first element by roll forming to form a rectangular cross section. A portable apparatus for making an enclosed cross-section building frame member from elongated, sheet metal first and second elements, includes a floor mounted frame having a front end and a spaced back end, an elongated guide tube, a mandrel, spaced, diametrically opposed first and second inner seaming roller sections, and first and second outer seaming roller sections. The guide tube is mounted to the front end of the frame and extends rearwardly. The guide tube is sized for assembly of the first and second elements. The mandrel extends rearwardly from the back end of the guide tube. The first and second inner seaming roller sections are mounted on the mandrel and each have a plurality of longitudinally spaced inner seaming rollers. The first and second outer seaming roller sections are mounted on the frame and each have a plurality of spaced, powered outer seaming rollers aligned with the inner seaming rollers.

BRIEF DESCRIPTION OF THE DRAWINGS

Details of this invention are described in connection with the accompanying drawings that bear similar reference numerals in which:

FIG. 1 is a partial perspective view of a building frame member embodying features of the present invention.

FIG. 2 is an end view of the frame member of FIG. 1.

FIG. 3 is an end view of the frame member of FIG. 1 prior to seaming.

FIG. 4 is a perspective view of several of the frame members of FIG. 1 assembled into a wall.

FIG. 5 is an end view of another building frame member embodying features of the present invention.

FIG. 6 is an end view of another building frame member embodying features of the present invention.

FIG. 7 is an end view of an element of the frame member of FIG. 6.

FIG. 8 is an end view of several of the frame members of FIG. 6 stacked together.

FIG. 9 is a perspective view of an apparatus for making an enclosed cross-section building frame member embodying features of the present invention.

FIG. 10 is a sectional view through line 10-10 of FIG. 9, with first and second elements assembled on the guide tube.

FIG. 11 is a perspective view of the inner and outer seaming roller sections of the apparatus of FIG. 10 with the intermediate outer seaming rollers removed.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 to 4, a building frame member 11, embodying features of the present invention, includes elongated, sheet metal first and second elements 14 and 15, connected together by diametrically opposed, double overlapped, first and second seams 17 and 18, to form a rectangular cross section. The first and second elements 14 and 15 are identical, and each has a planar first wall 20 and a substantially planar second wall 21. The first wall 14 has a first edge 23, a spaced second edge 24, a right angle first corner 26 at the first edge 23, and a right angle second corner 27 at the second edge 24.

Describing the specific embodiments herein chosen for illustrating the invention, certain terminology is used which will be recognized as being employed for convenience and having no limiting significance. For example, with regard to the frame members, the terms “inwardly” and “outwardly” will refer to the illustrated embodiment relative to the enclosed space within the frame members. With regard to the apparatus for making the frame member, the terms “front” and “back” refer to the upstream, entry end and the downstream, exit end of the apparatus, respectively. Further, all of the terminology above-defined includes derivatives of the word specifically mentioned and words of similar import.

The first corner 26 connects the first and second walls 20 and 21. A first seam portion 29 extends from the second wall 21, opposite the first corner 26. The first seam portion 29 has an inclined section 30 that slants inwardly from the second wall 21, a flat first hook section 31 that extends from the inclined section 30 parallel to said second wall 21, a U shaped end section 32 that curves outwardly from the first hook section 31, and a spaced, flat second hook section 33 that extends from the end section 32 back towards the inclined section 30, parallel to the first hook section 31.

A second seam portion 35 has flat first hook section 36 that extends from the second corner 27, a U shaped end section 37 that curves inwardly from the first hook section 36, and a spaced, flat second hook section 38 that extends from the end section 37 back towards the first wall 20, parallel to the first hook section 36.

The first seam 17 is formed from the first seam portion 29 of the first element 14 and the second seam portion 35 of the second element 15. The second seam 18 is formed from the first seam portion 29 of the second element 15 and the second seam portion 35 of the first element 14.

The second hook section 33 of the first seam portion 29 of the first element 14 fits between the first and second hook sections 36 and 38 of the second seam portion 35 of the second element 15. The second hook section 38 of the second seam portion 35 of the second element 15 fits between the first and second hook sections 31 and 33 of the first seam portion 29 of the first element 14. The end section 32 of the first seam portion 29 of the first element 14 abuts the first wall 20 of the second element 15 and the end section 37 of the second seam portion 35 of the second element 15 abuts the inclined section 30 of the first seam portion 29 of the first element 14 to secure the first seam 17.

The second hook section 33 of the first seam portion 29 of the second element 15 fits between the first and second hook sections 36 and 38 of the second seam portion 35 of the first element 14. The second hook section 38 of the second seam portion 35 of the first element 14 fits between the first and second hook sections 31 and 33 of the first seam portion 29 of the second element 15. The end section 32 of the first seam portion 29 of the second element 15 abuts the first wall 20 of the first element 14 and the end section 37 of the second seam portion 35 of the first element 14 abuts the inclined section 30 of the first seam portion 29 of the second element 15 to secure the second seam 18.

The inclined section 30 of the first seam portion 29 of the first element 14 is sized such that the first hook section 36 of the second seam portion 35 of the second element 15 is coplanar with the second wall 21 of the first element 14. The inclined section 30 of the first seam portion 29 of the second element 15 is sized such that the first hook section 36 of the second seam portion 35 of the first element 14 is coplanar with the second wall 21 of the second element 15. The first and second seams 17 and 18 are cross serrated to prevent longitudinal slippage between the first and second elements 14 and 15.

The first and second elements 14 and 15 are substantially L shaped prior to the final forming of the first and second seams 17 and 18, as shown in FIG. 3. Prior to forming the first and second seams 17 and 18, the second hook section 33 of the first seam portion 29 projects outwardly, perpendicular to the second wall 21, and the first hook section 36 of the second seam portion 35 projects outwardly, coplanar with the first wall 20. These L shaped elements can be formed at a factory, compactly stacked for shipping, and assembled and seamed at a job site.

The frame member 11 is assembled with the second hook section 33 of the first seam portion 29 of the first element 14 between the first and second hook sections 36 and 38 of the second seam portion 35 of the second element 15 and the second hook section 33 of the first seam portion 29 of the second element 15 fits between the first and second hook sections 36 and 38 of the second seam portion 35 of the first element 14. The second seam portion 35 of the second element 15 and the second hook section 33 of the first seam portion 29 of the first element 14 are folded towards the second wall 21 of the first element 14 to create the second corner 27 of the second element 15 and the end section 32 of the first seam portion 29 of the first element 14 and form the first seam 17. The second seam portion 35 of the first element 14 and the second hook section 33 of the first seam portion 29 of the second element 15 are folded towards the second wall 21 of the second element 15 to create the second corner 27 of the first element 14 and the end section 32 of the first seam portion 29 of the second element 15 and form the second seam 18.

In the building frame member 11 shown in FIGS. 1 to 4 the first walls 20 are longer than the second walls 21 of the first and second elements 14 and 15, such that the first and second seams 17 and 18 are on the “ends” of the building frame member 11. Alternatively, the first walls 20 can be shorter than the second walls 21 of the first and second elements 14 and 15, so that the first and second seams 17 and 18 are on the “sides” of the building frame member 11. FIG. 4 shows a wall 39 with a plurality of spaced building frame members 11 as studs connected at the bottom to a “Cee”-shaped sill plate 40 and at the top to a “Cee”-shaped header 41.

FIG. 5 shows another building frame member 42, embodying features of the present invention, with elongated, sheet metal first and second elements 44 and 45, connected together by diametrically opposed, double overlapped, first and second seams 47 and 48, to form a rectangular cross section. The first and second elements 44 and 45 each have a planar first wall 50, a substantially planar second wall 51 and a substantially planar third wall 52. The first wall 50 has a first edge 53, a spaced second edge 54, a right angle first corner 56 at the first edge 53, and a right angle second corner 57 at the second edge 54.

The first corner 56 connects the first and second walls 50 and 51. The second corner 56 connects the first and third walls 50 and 52. The first seam 47 connects the second wall 51 of the first element 44 to the third wall 52 of the second element 45, intermediate the first corner 56 of the first element 44 and the second corner 57 of the second element 45. The second seam 48 connects the second wall 51 of the second element 45 to the third wall 52 of the first element 44, intermediate the first corner 56 of the second element 45 and the second corner 57 of the first element 44. The second wall 51 of the first element 44 and the third wall 52 of the second element 45 are coplanar and the first seam 47 shown is indented inwardly. The second wall 51 of the second element 45 and the third wall 52 of the first element 44 are coplanar and the second seam 48 shown is indented inwardly.

As shown in FIGS. 6 to 8, another building frame member 62, embodying features of the present invention, includes elongated, sheet metal first and second elements 64 and 65, connected together by diametrically opposed, double overlapped, first and second seams 67 and 68, to form an I shaped or hourglass cross section. The first and second elements 64 and 65 are identical, and each have a shaped first wall 70 and a substantially planar second wall 71. The second wall 71 has a first edge 73, a spaced second edge 74, a right angle first corner 76 at the first edge 73, and a right angle second corner 77 at the second edge 74.

The first corner 76 connects the first and second walls 70 and 71. The first seam 67 connects the first wall 70 of the first element 64 to the second corner 77 of the second wall 71 of the second element 65. The second seam 68 connects the first wall 70 of the second element 65 to the second corner 77 of the second wall 71 of the first element 64. The first wall 70 is shaped with a pair of coplanar outer sections 79 that extend towards each other from opposite edges of the first wall 70, inclined sections 80 that each slant inwardly from one of the outer sections 79 to a middle section 81 that is parallel with and spaced inwardly from the outer sections 79.

Preferably the width of the middle section 81 is about twice the width of each outer section 79, so that the frame members 62 can be efficiently stacked in staggered rows, as shown in FIG. 8. The shaped first wall 70 permits higher weight to volume stacking for shipment, and equal or greater structural strength when compared to rectangular frame members. The first and second seams 67 and 68 can alternatively be placed on the second wall 71, in the middle or at the second corner 77.

A method of making a building frame member includes the steps of providing identical, compactly stackable, substantially L-shaped elongated, sheet metal first and second elements, assembling the first and second elements, forming a first seam and forming a second seam. The first and second elements each have a first wall with a first edge and a spaced second edge, a right angle first corner at the first edge, a second wall extending from the first corner, a partially formed first seam portion extending from the second wall and a partially formed second seam portion extending from the second edge. The first and second elements are assembled with the first corners diametrically opposed, the first seam portion of the first element fitting with the second seam portion of the second element and the first seam portion of the second element fitting with the second seam portion of the first element. The first seam is formed by roll forming the first seam portion of the first element and the second seam portion of the second element, and the second seam is formed by roll forming the first seam portion of the second element and the second seam portion of the first element.

The method includes forming the first seam and forming the second seam simultaneously. The method also includes the step of cross serrating the first and second seams. The step of forming a first seam includes forming a double overlapped seam and the step of forming a second seam includes forming a double overlapped seam.

Referring to FIGS. 9 to 11, a portable apparatus 84 for making an enclosed cross-section building frame member from elongated, sheet metal first and second elements, embodying features of the present invention, includes a frame 86, an elongated guide tube 87, a mandrel 88, first and second inner seaming roller sections 89 and 90, and first and second outer seaming roller sections 91 and 92.

The frame 86 is floor mounted and supported by a plurality of legs 94. The frame 86 has a front end 95 and a spaced back end 96. A support plate 97 is mounted on the front end 95 and projects upwardly. The guide tube 87 has a front end 99 that is mounted on the support plate 97. The front end 99 of the guide tube 87 supports the guide tube 87 and the guide tube 87 is spaced above the frame 86.

The guide tube 87 extends rearwardly to a spaced back end 100. The length of the guide tube 87 is selected to be greater than the longest building frame member to be made on the apparatus 84 to allow assembly of the first and second elements, such as first and second elements 14 and 15 of frame member 11 on the guide tube 87. The guide tube 87 has a cross sectional size that allows assembly of the first and second elements, as shown in FIG. 10.

The mandrel 88 is mounted to and supported by the back end 100 of the guide tube 87. The mandrel 88 extends rearwardly from the back end 100 of the guide tube 87 to substantially the back end 96 of the frame 86. The first and second inner seaming roller sections 89 and 90 are mounted on the mandrel. The first and second inner seaming roller sections 89 and 90 are spaced and diametrically opposed. The first and second inner seaming roller sections 89 and 90 each have a plurality of longitudinally spaced inner seaming rollers 102.

The first and second outer seaming roller sections 91 and 92 are mounted on the frame 86. The first and second outer seaming roller sections 91 and 92 each include a plurality of spaced, powered outer seaming rollers 103 that are aligned with the inner seaming rollers 102. The first and second outer seaming roller sections 91 and 92 each include a forwardly located initial stage outer seaming roller 103 that is a traction gear 105 that provides traction to pull the elements. The first and second outer seaming roller sections 91 and 92 each include a rearwardly located final stage outer seaming roller 103 that is a cross serrating gear 106 that cross serrates the first and second seams, respectively.

The inner seaming rollers 102 on the first and second inner seaming roller sections 89 and 90 are longitudinally aligned so that the first and second seams are formed simultaneously. The mandrel 88 is interchangeable to accommodate forming of different sizes of frame members, such as 2×4, 2×6 and 2×8. The first outer seaming section 91 is also adjustable to accommodate forming of different sizes of frame members.

Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. 

What is claimed is:
 1. A building frame member comprising: an elongated, sheet metal first element having a first wall extending from a right angle first corner to a spaced right angle second corner and a planar second wall extending from said first corner, an elongated sheet metal second element having a first wall extending from a right angle first corner to a spaced right angle second corner and a planar second wall extending from said first corner, a roll formed, double overlapped first seam located between said first corner of said first element and said second corner of said second element and connecting said second wall of said first element to said second corner of said second element, and a diametrically opposed, roll formed, double overlapped second seam connecting said second wall of said second element to said second corner of said first element, whereby said first and second elements form a closed shape.
 2. The frame member as set forth in claim 1 wherein: said first element has a first seam portion extending from said second wall and a second seam portion extending from said second corner, said second element has a first seam portion extending from said second wall and a second seam portion extending from said second corner, said first seam is formed from said first seam portion of said first element and said second seam portion of said second element, and said second seam is formed from said first seam portion of said second element and said second seam portion of said first element.
 3. The frame member as set forth in claim 2 wherein: said first seam portions of said first and second elements each have an inwardly inclined section extending from said second wall, a first hook section that extends from said inclined section parallel to said second wall, an end section that curves outwardly from said first hook section, and a spaced second hook section that extends from said end section towards said inclined section, parallel to said first hook section, said second seam portions of said first and second elements each have a first hook section that extends from said second corner, an end section that curves inwardly from said first hook section, and a spaced second hook section that extends from said end section towards said first wall, parallel to said first hook section, said second hook section of said first seam portion of said first element is received between said first and second hook sections of said second seam portion of said second element, and said second hook section of said second seam portion of said second element is received between said first and second hook sections of said first seam portion of said first element, said second hook section of said first seam portion of said second element is received between said first and second hook sections of said second seam portion of said first element, and said second hook section of said second seam portion of said first element is received between said first and second hook sections of said first seam portion of said second element, and said first hook section of said second seam portion of said first element is coplanar with said second wall of said second element, and said first hook section of said second seam portion of said second element is coplanar with said second wall of said first element.
 4. The frame member as set forth in claim 1 wherein said first seam is adjacent to said second corner of said second element and second seam is adjacent to said second corner of said first element.
 5. The frame member as set forth in claim 1 wherein said first seam is spaced intermediate said first corner of said first element and said second corner of said second element, and second seam is spaced intermediate said first corner of said second element and said second corner of said first element.
 6. The frame member as set forth in claim 1 wherein said first and second seams are cross serrated.
 7. The frame member as set forth in claim 1 wherein said first and second elements are identical.
 8. The frame member as set forth in claim 1 wherein said first walls of said first and second elements are planar, whereby said first and second elements form a closed rectangular shape.
 9. The frame member as set forth in claim 1 wherein said first walls of said first and second elements are shaped such that said first and second elements form a closed hourglass shape
 10. A building frame member comprising: an elongated sheet metal first element having a planar first wall extending from a right angle first corner to a spaced right angle second corner, a planar second wall extending from said first corner, a first seam portion extending from said second wall and a second seam portion extending from said second corner, an elongated sheet metal second element, identical to said first element, having a planar first wall extending from a right angle first corner to a spaced right angle second corner, a planar second wall extending from said first corner, a first seam portion extending from said second wall and a second seam portion extending from said second corner, a roll formed, double overlapped first seam located between said first corner of said first element and said second corner of said second element, formed from said first seam portion of said first element and said second seam portion of said second element, and connecting said second wall of said first element to said second corner of said second element, and a diametrically opposed, roll formed, double overlapped second seam formed from said first seam portion of said second element and said second seam portion of said first element, and connecting said second wall of said second element to said second corner of said first element, whereby said first and second elements form a closed, substantially rectangular shape.
 11. A method of making a building frame member comprising the steps of: providing identical, compactly stackable, substantially L-shaped elongated, sheet metal first and second elements each having a first wall with a first edge and a spaced second edge, a right angle first corner at said first edge, a planar second wall extending from said first corner, a partially formed first seam portion extending from said second wall and a partially formed second seam portion extending from said second edge, assembling said first and second elements with said first corners diametrically opposed, said first seam portion of said first element fitting with said second seam portion of said second element and said first seam portion of said second element fitting with said second seam portion of said first element, forming a first seam by roll forming said first seam portion of said first element and said second seam portion of said second element, and forming a second seam by roll forming said first seam portion of said second element and said second seam portion of said first element.
 12. The method as set forth in claim 11 wherein said steps of forming a first seam and forming a second seam are performed simultaneously.
 13. The method as set forth in claim 11 including the step of cross serrating said first and second seams.
 14. The method as set forth in claim 13 wherein said step of forming a first seam includes forming a double overlapped seam and said step of forming a second seam includes forming a double overlapped seam.
 15. A portable apparatus for making an enclosed cross-section building frame member from elongated, sheet metal first and second elements, comprising: a floor mounted frame having a front end and a spaced back end, an elongated guide tube spaced above said frame and having a front end mounted to said front end of said frame and supporting said guide tube, said guide tube extending rearwardly to a spaced back end, said guide tube being sized for assembly of said first and second elements, a mandrel mounted to and supported by said back end of said guide tube, said mandrel extending rearwardly from said back end of said guide tube to said back end of said frame, spaced, diametrically opposed first and second inner seaming roller sections mounted on said mandrel, said first and second inner seaming roller sections each having a plurality of longitudinally spaced inner seaming rollers, and first and second outer seaming roller sections mounted on said frame, said first and second outer seaming roller sections each having a plurality of spaced, powered outer seaming rollers aligned with said inner seaming rollers, whereby said first and second elements are assembled on said guide tube and said inner and outer seaming rollers form diametrically opposed first and second seams between said first and second elements to form said frame member.
 16. The apparatus as set forth in claim 15 wherein said first and second outer seaming roller sections each include a forwardly located initial stage outer seaming roller that is a traction gear, said gears providing traction to pull said first and second elements through said inner and outer seaming rollers.
 17. The apparatus as set forth in claim 15 wherein said first and second outer seaming roller sections include rearwardly located final stage outer seaming rollers that are cross serrating gears that cross serrates said first and second seams.
 18. The apparatus as set forth in claim 15 wherein said inner seaming rollers on said first inner seaming roller section and said inner seaming rollers on said second inner seaming roller section are longitudinally aligned such that said first and second seams are formed simultaneously.
 19. The apparatus as set forth in claim 15 wherein said mandrel is interchangeable to accommodate forming of different sizes of frame members.
 20. The apparatus as set forth in claim 19 wherein said first outer seaming section is adjustable to accommodate forming of different sizes of frame members. 